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Each Hercules propeller is

as unique as the

aircraft it was made for

To optimise performance, every different aircraft type needs a unique propeller design. A propeller that has been finitely designed for a given aircraft, engine and intended use enables the aircraft to perform to the maximum.


A correctly designed and well made propeller will help to:


Reduce take-off distance

Improve rate of climb

Increase cruise speed

Improve fuel economy

Quicken throttle response

Reduce engine vibration

Reduce noise

Aerodynamic design output


For every new design, all the different attributes of a propeller are adjusted to suit the airframe, engine and expected performance.


There is more to constructing an efficient propeller design than simply adjusting pitch and diameter. Also to be considered are pitch distribution, taper ratio, camber ratio and aspect ratio.


All of these parameters interact with each other – our advanced computer design software balances them all to create the most appropriate aerodynamics.

Computer aided manufacturing

(CAM) simulation

Once the new propeller design has been finalised, a 3D CAD model is created. The CAD model is processed to create the programs that the CNC machine follows when making the propeller.

If you have a specific requirement for a propeller to optimise your aircraft’s performance, whether your machine is a vintage pioneer or a composite speed machine, please contact us, we can design and manufacture a propeller just for you.

Planform design options

Although flight performance is the most important consideration to all of our propeller designs, we can also design the planform shape of the propeller to appropriately match the aircraft it is intended for.  


The majority of the propellers we design and manufacture have a symmetrical planform but we can also give the blade shape a classic curved shape for vintage aircraft and replicas. 


If you have a particular requirement, please enquire – it is more than likely we can design and make it for you.

Spitfire tips

Inspired by what could be the most famous fighter of all time, Hercules Propellers designed with our symmetrical plan forms have ‘spitfire tips’.


Just like the fighter, there is far more to it than just good looks, this profile greatly improves efficiency by minimising induced drag and reducing noise.

Conical hubs

Once a common feature of wooden propellers, the hub part of the propeller would sometimes be conical in shape.


Featuring tapering sides which when fitted with a skull cap spinner, form an aerodynamic shape, blending the propeller into the engine cowling. 


Creating bespoke propeller hubs to the original or your own specification is no problem for us to achieve.  If your propeller requires a special design feature, please ask, it is more than likely we can do it.


Powerful computer technology makes our propellers affordable

Using our sophisticated computer program to number crunch the formulae, we calculate the optimum propeller design for your aircraft, fine tuning all the different aspects of the propeller blade design. There is far more to getting the best out of a propeller than simply adjusting pitch and diameter.


Input data includes airframe dimensions and weight, engine power and rpm, expected performance and any special requirement such as long distance touring, air-racing, bush flying, stol performance or aerobatics. Once the new propeller design has been finalised, a 3d cad model is created.  The cad model is processed to create the programs that the cnc machine follows when making the propeller.

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